Orthopedic adjustment mechanism for an orthopedic brace

ABSTRACT

An adjustment device for attachment to an orthopedic brace having a connecting plate upon which an inner disk is secured. The inner disk contains a patterned section which forms an interlocking coupling with a patterned portion of an outer disk to releasably interlock the inner disk to the outer disk.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit under 35 U.S.C. §119(e) ofU.S. Provisional Application No. 60/299,496, filed on Jun. 20, 2001.

FIELD OF THE INVENTION

[0002] This invention relates to an adjustment device for an orthopedicbrace. More particularly, this invention relates to an adjustment devicefor an orthopedic brace that allows for the orthopedic brace to beadjusted both laterally and angularly to a desired position, whilecomprising an attachment assembly that minimizes lateral and angularmovements after the desired position of the orthopedic brace has beenobtained.

BACKGROUND OF THE INVENTION

[0003] Current orthopedic braces are manufactured in standard unisexsizes: small, medium, large, etc. However, in order for these orthopedicbraces to be custom fit to various individual users, these braces mustprovide for some adjustability to compensate for the variation in thebodily dimensions of the various users even after the users have beensubdivided into small, medium, large, etc. categories.

[0004] Current hip braces, for example, provide for angular as well aslateral adjustment. The angular adjustment is provided to compensate forthe anatomical differences between male and female patients. The pelvicstructure of a typical female is angled more widely with respect tovertical than the pelvic structure of the typical male. The lateraladjustment is provided to compensate for the differences in the waistsizes of the various users of the hip braces.

[0005] A current hip brace comprises a semi-rigid plate to which two hipbrace shells are attached. After the hip brace shells have been placedto a desired position on the hips of the intended user, the left shellis attached to the plate by screwing an outer disk to an inner disk. Acompression force produced by screwing the disks together holds the leftshell to the plate. However, in order to screw the disks together, theuser of the brace, who has typically just undergone hip surgery, mustroll on his or her side in order for the person adjusting the brace tobe able to reach behind the user's back, where the plate is located, andinsert, then rotate, an alien wrench into a hexagon hole located on theface of the outer disk. Sitting in this position typically places theuser of the brace in a considerable amount of pain, especially if theuser has just undergone hip surgery.

[0006] In addition to the compression forces exerted on the left shelland the plate by the inner and outer disks, amplified frictional forceshelp reduce unwanted angular or lateral movement between the left shelland the plate once the desired position of the brace has been obtained.The amplified frictional forces are produced by securing texturedsurfaces, such as sandpaper, to an outside portion of the left shell andto an inside portion of the plate. The description above applies equallyto the relationship between the right shell and the plate. However, thisarrangement does not adequately prevent relative movement between theshells and the plate when large forces are applied to the brace or whenthe brace is used for an extended period of time.

[0007] Consequently, an improved adjustment device for orthopedic bracesis needed to address the problems of the prior art.

SUMMARY OF THE INVENTION

[0008] The present invention addresses the above-referenced problems byproviding an inner disk having a patterned section which mates with apatterned portion of an outer disk to releasably interlock the innerdisk to the outer disk, and thereby minimize relative motion between anorthopedic brace and the adjustment device of the present invention whenthe orthopedic brace is adjusted to a desired angular and lateralposition with respect to the adjustment device.

[0009] In addition, the inner disk and the outer disk are compressedtogether by securing an attachment knob to the inner disk. Avoiding theproblem of the prior art, the attachment knob can be secured to theinner disk by manually turning an ergonomically designed portion of theattachment knob so that a doctor can perform each of the steps ofloosening the attachment knobs, adjusting the orthopedic brace withrespect to the adjustment device, and tightening the attachment knobs,all with only a minimal movement on the part of the user.

[0010] Other objects, advantages and novel features of the presentinvention will become apparent from the following detailed descriptionof the invention when considered in conjunction with the accompanyingdrawings.

DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is an exploded perspective view of an adjustment device foran orthopedic brace of the present invention;

[0012]FIG. 2 is a perspective view of an inner surface of an inner disk.This view shows one embodiment of a patterned section on the inner diskwhich is used to interlock with a pattered portion of an outer disk;

[0013]FIG. 3 is a perspective view of a top surface of an attachmentknob. This view shows one embodiment of an ergonomic design of theattachment knob which allows the knob to be manually turned without theneed for a tool;

[0014]FIG. 4 is a perspective view of a partial assembly of theadjustment device of FIG. 1; and

[0015]FIG. 5 is a perspective view of an orthopedic hip device utilizingthe adjustment device of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0016] An adjustment device 10 for an orthopedic brace of the presentinvention is shown in FIGS. 1-3. The adjustment device 10 comprises asemi-rigid connecting plate 12 to which an 15 orthopedic brace,partially shown in FIG. 1 as an orthopedic brace attachment arm 18, isreleasably locked into position utilizing an inner disk 14, and an outerdisk 16. The inner disk 14 is secured to the plate 12 and forms aninterlocking coupling with the outer disk 16. The outer disk 16 mateswith the orthopedic brace attachment arm 18 and is secured to the innerdisk 14 by use of an attachment knob 20.

[0017] In one embodiment, the plate 12 comprises an opening 22, such asa circular opening and the inner disk 14 comprises a patterned section24 (shown in FIG. 2). The patterned section 24 can, for example,protrude from the inner disk 14 and have a shape similar to the shape ofthe plate opening 22 such that the patterned section 24 fits snugly intothe plate opening 22. The inner disk 14 can be secured to the plate 12utilizing a variety of methods. For instance, the inner disk 14 can havea plurality of protruding members (not show) which may be press fit intoa matching plurality of openings 28 in the plate 12, and then sonicwelded into position. Alternatively, the inner disk 14 may have aplurality of holes 30 which match the plurality of openings 28 in theplate 12. Rivets or set screws, for example, may be inserted through theplurality of holes 30 and into the openings 28 to secure the inner disk14 to the plate 12, or the openings 28 may be internally threaded toreceive standard screws. In another embodiment, a separate inner disk 14component is not required, instead, a patterned section 24 is integralto the plate 12 itself.

[0018] The patterned section 24 of the inner disk 14 forms a releasable,interlocking coupling with a patterned portion 32 of the outer disk 16.The patterned section 24 and the patterned portion 32 can be a widevariety of patterns that cause interlocking to occur between the innerdisk 14 and the outer disk 16. In one instance, the patterned portion 32comprises a plurality of grooves 34, such as v-grooves, which releasablyinterlock with a mating plurality of grooves 26, such as v-grooves, inthe patterned section 24 of the inner disk 14. In one particularembodiment, the plurality of grooves 34 and 26, in this case v-grooves,in the outer disk 16 and inner disk 14, respectively, are positioned ina radial pattern, wherein the v-grooves of the outer disk 16 are equallyspaced 8 degrees apart such that 45 v-grooves exist in the patternedportion 32 of the outer disk 16 and the v-grooves of the inner disk 14are equally spaced 8 degrees apart such that a mating 45 v-grooves existin the patterned section 24 of the inner disk 14. Thus, enabling theadjustment device 10 to rotate 8 degrees, with respect to theaccompanying orthopedic brace, per interlocking position between theinner disk 14 and the outer disk 16. This pattern can be produced, forexample, by injection molding a material of 30% glass filled nylon, oranother suitable material, or by machining grooves into the basematerial.

[0019] To secure the orthopedic brace to the adjustment device 10, aslot, such as a lateral slot, is produced in a section of the orthopedicbrace, shown in FIG. 1 as slot 36 in orthopedic brace attachment arm 18.The outer disk 16 comprises a slot pin 33. The slot pin 33 slidablycommunicates with the slot 36 during lateral adjustments of theorthopedic brace with respect to the adjustment device 10. To facilitatethese lateral adjustments, the slot pin 33 may be of a similar size andshape as the slot 36. In one embodiment, the patterned portion 32 isformed in the shape of the slot pin 33. As a result, the patternedportion functions as a slot pin, and two separate pieces are notrequired.

[0020] When the attachment arm 18 slot 36 is positioned adjacent to theplate opening 22, the patterned portion 32 of the outer disk 16 can bethreaded through the slot 36 such that the patterned portion 32 of theouter disk 16 can be interlocked with the patterned section 24 of theinner disk 14. In one instance, the patterned portion 32 protrudes fromthe surface of the outer disk 16, enabling the patterned portion 32 toextend through the slot 36 and reach the patterned section 24 of theinner disk 14, allowing the inner disk 14 and the outer disk 16 to beengaged an interlocked coupling.

[0021] When the slot pin 33 of the outer disk 16 is placed within theslot 36 of the attachment arm 18, and the patterned portion 32 of theouter disk 16 is interlocked with the patterned section 24 of the innerdisk 14, the attachment knob 20 can be secured to the inner disk 14.This, in turn, secures both the outer disk 16 to the attachment arm 18,and the attachment arm 18 to the plate 12. In one embodiment, theattachment knob 20 comprises a protruding member 38 having externalthreads, such as a screw. In this embodiment, the protruding member 38extends through an opening 40 in the outer disk 16, through the slot 36in the attachment arm 18 and into an internally threaded section 42 ofthe inner disk 14. In this arrangement, rotating the attachment knob 20in a clockwise direction (assuming right handed threads) threads theprotruding member 38 into the internally threaded section 42 of theinner disk 14. As a result, a compression force is produced, exerting acompression force on the outer disk 16, the attachment arm 18, and theplate 12. The compression force holds each of these components together.

[0022]FIG. 3 shows a top surface 21 of the attachment knob 20. The topsurface 21 of the attachment knob 20 comprises an ergonomic design 23.The ergonomic design 23 allows the attachment knob 20 to be bothmanually attached to the inner disk 14 and manually unattached to theinner disk 14 without the need for a tool. In one particular embodiment,the ergonomic design 23 is a section which protrudes from the topsurface 21 of the attachment knob 20 in the shape of a cross, or theletter “X”. However, other ergonomic designs may be used.

[0023] Although the above discussion has focused on only the left sideof the adjustment device 10, the descriptions used above are accuratefor the right side of the adjustment device 10 as well and are omittedfrom the present discussion to avoid duplicity.

[0024] For illustrative purposes, FIG. 4 shows a partially assembledadjustment device 10. For visual clarity, the adjustment device 10 asshown is only attached to one orthopedic brace attachment arm 18.

[0025]FIG. 5 shows the adjustment device 10 of the present inventionincorporated into an orthopedic hip brace 44. This brace 44 comprises aright hip shell 46, a left hip shell 48, a generally flexible frontportion 50, an adjustment belt 52 and the adjustment device 10 of thecurrent invention.

[0026] Typically, an orthopedic brace which incorporates an adjustmentdevice, such as the adjustment device 10 of the current invention, isfitted to a user by a doctor or an orthopedic specialist. To custom fitthe hip brace 44 to a user, the doctor typically lays the user flat onthe user's back (in many cases the user has recently undergone hipsurgery, therefore laying the user in any other position or standing theuser is extremely painful to the user). The adjustment belt 52 can bedetached from the hip brace 44 using a latch 54. Detaching the belt 52allows the front portion 50 of the brace 44 to be opened. In the openedposition, the brace 44 can be wrapped around the user's waist. Thedoctor can then place the hip shells 46 and 48 against the user's hips.Most likely, the doctor will then need to adjust the hip shells 46 and48 both angularly and laterally in order to custom fit the brace 44 tothe user. With the user still laying on his or her back, the doctor canreach behind the user, manually loosen the attachment knobs (right andleft) 20 of the adjustment device 10, reposition the brace 44, and thenmanually tighten the attachment knobs 20. This operation requires only aminimum of movement by the user from the user's initial lying position.This manual adjustment of the attachment knobs 20 is an advantage overprior adjustment devices which require the use of an adjustment tool,such as an allen wrench, to loosen the adjustment device. Because anadjustment tool is required to adjust the adjustment device of the priorart, the doctor must move the user onto the user's side in order to fitthe adjustment tool into the adjustment device. This is typically verypainful to the user, especially one who has just undergone hip surgery.

[0027] After the attachment knobs 20 have been loosened, the shells 46and 48 can be easily adjusted in the lateral direction by sliding theslot pin 33 of the outer disk 16 along the orthopedic brace attachmentarm 18 slot 36 until a desired lateral position of each shell 46 and 48is obtained, i.e. when the shell fits snugly against the user's hips inthe lateral position. To adjust the shells 46 and 48 angularly, theouter disk 16 is disengaged from its interlocked coupling with the innerdisk 14, and then rotated until a desired angular orientation isachieved. When the desired angular orientation is achieved, the outerdisk 16 can be re-engaged to the inner disk 14 such that the disks 14and 16 form an interlocking coupling. Since slot pin 33 is of a similarsize and shape as the attachment arm 18 slot 36, rotating the outer disk16 produces a rotational force that the slot pin 33 translates to theattachment arm 18 slot 36, thus angularly repositioning the orthopedicbrace attachment arm 18 with respect to the adjustment device 10. Anadvantage that this arrangement provides is that once the brace 44 isadjusted to a desired lateral and angular position, the interlockingpattern of the patterned section 24 of the inner disk 14 and thepatterned portion 32 of the outer disk 16 interlocks the disks 14 and 16together such that the relative movement between the disks 14 and 16 isminimized. In addition, since the slot pin 33 is attached to the outerdisk 16 and the slot pin 33 is of a similar size and shape of theattachment arm 18 slot 36, relative motion between the outer disk 16 andthe orthopedic brace attachment arm 18 is minimized and thus relativemotion between the adjustment device 10 and the orthopedic braceattachment arm 18 is minimized.

[0028] Although the present invention has been described and illustratedwith respect to a preferred embodiment thereof, it is to be understoodthat the invention is not to be limited since changes and modificationsare within the intended scope of the invention as hereinafter claimed.

1. An adjustment device for attachment to an orthopedic bracecomprising: a connecting plate; an inner disk attached to the connectingplate, the inner disk having a patterned section; and an outer diskhaving a patterned portion which forms an interlocking coupling with thepatterned section of the inner disk to releasably interlock the innerdisk to the outer disk.
 2. The adjustment device of claim 1 furthercomprising: an attachment knob having an extending member, wherein theattachment knob applies a compressive force to the outer disk to securethe outer disk to the inner disk when the extending member is mated withthe inner disk.
 3. The adjustment device of claim 2 wherein the outerdisk mates with an orthopedic brace attachment arm having a slot, theouter disk slidably communicates with the attachment arm slot to allowfor a lateral adjustment of the orthopedic brace.
 4. The adjustmentdevice of claim 3, wherein the outer disk may be disengaged from theinner disk and rotated with respect to the inner disk to cause theattachment arm to rotate with respect to the connecting plate when theouter disk is mated with the attachment arm slot.
 5. The adjustmentdevice of claim 4, wherein the outer disk comprises a protruding sectionwhich is substantially similar to the shape of the attachment arm slotsuch that the protruding section mates with the attachment arm slot. 6.The adjustment device of claim 5, wherein the patterned section of theinner disk and the patterned portion of the outer disk each comprise aplurality of v-grooves arranged in a radial pattern wherein a centerline of each v-groove is radially spaced a same number of degrees froman adjacent v-groove centerline.
 7. The adjustment device of claim 6,wherein the adjustment knob comprises an ergonomic design such that theknob can be manually attached to and detached from the inner diskwithout the use of tools.
 8. The adjustment device of claim 7, whereinthe orthopedic brace is an orthopedic hip brace.
 9. An adjustment devicefor attachment to an orthopedic brace comprising: a connecting platehaving an opening; an inner disk having a patterned raised section whichmates with the connecting plate opening; and an outer disk having apatterned protruding portion which forms an interlocking coupling withthe patterned raised section of the inner disk to releasably interlockthe inner disk to the outer disk.
 10. The adjustment device of claim 9further comprising: an attachment knob having an externally threadedextending member, wherein the attachment knob applies a compressiveforce to the outer disk to secure the outer disk to the inner disk whenthe externally threaded extending member is mated with an internallythreaded section of the inner disk.
 11. The adjustment device of claim10 wherein the protruding portion of the outer disk mates with anorthopedic brace attachment arm having a slot, the protruding portionhaving a shape which is substantially similar to the shape of theattachment arm slot such that the protruding portion mates with theattachment arm slot.
 12. The adjustment device of claim 11, wherein theprotruding portion mates with the attachment arm slot to allow for alateral adjustment of the orthopedic brace when the attachment arm isdisposed between the connecting plate and the outer disk.
 13. Theadjustment device of claim 12, wherein rotating the outer disk withrespect to the inner disk causes the orthopedic brace attachment arm torotate with respect to the connecting plate when the outer disk is matedwith the orthopedic brace attachment arm slot.
 14. The adjustment deviceof claim 13, wherein the patterned raised section of the inner disk andthe patterned protruding portion of the outer disk each comprise aplurality of v-grooves arranged in a radial pattern wherein a centerline of each v-groove is radially spaced a same number of degrees froman adjacent v-groove centerline.
 15. The adjustment device of claim 14,wherein the adjustment knob comprises an ergonomic design such that theknob can be manually attached to and detached from the inner diskwithout the use of tools.
 16. An adjustment device for attachment to anorthopedic hip brace comprising: a connecting plate having a firstopening and a second opening; a first inner disk having a patternedraised section which mates with the connecting plate first opening; asecond inner disk having a patterned raised section which mates with theconnecting plate second opening; a first outer disk having a patternedprotruding portion which forms an interlocking coupling with thepatterned raised section of the inner disk to releasably interlock theinner disk to the outer disk; and a second outer disk having a patternedprotruding portion which forms an interlocking coupling with thepatterned raised section of the inner disk to releasably interlock theinner disk to the outer disk.
 17. The adjustment device of claim 16further comprising: a first attachment knob having an externallythreaded extending member, wherein the first attachment knob applies acompressive force to the first outer disk to secure the first outer diskto the first inner disk when the externally threaded extending member ofthe first attachment knob is mated with an internally threaded sectionof the first inner disk; and a second attachment knob having anexternally threaded extending member, wherein the second attachment knobapplies a compressive force to the second outer disk to secure thesecond outer disk to the second inner disk when the externally threadedextending member of the second attachment knob is mated with aninternally threaded section of the second inner disk.
 18. The adjustmentdevice of claim 17 wherein: the protruding portion of the first outerdisk mates with a first orthopedic hip brace attachment arm having aslot, the protruding portion of the first outer disk having a shapewhich is substantially similar to the shape of the first attachment armslot such that the protruding portion of the first outer disks mateswith the first attachment arm slot to allow for a first lateraladjustment of the orthopedic hip brace when the first attachment arm isdisposed between the connecting plate and the first outer disk; and theprotruding portion of the second outer disk mates with a secondorthopedic hip brace attachment arm having a slot, the protrudingportion of the second outer disk having a shape which is substantiallysimilar to the shape of the second attachment arm slot such that theprotruding portion of the second outer disks mates with the secondattachment arm slot to allow for a second lateral adjustment of theorthopedic hip brace when the second attachment arm is disposed betweenthe connecting plate and the second outer disk.
 19. The adjustmentdevice of claim 18, wherein: rotating the first outer disk with respectto the first inner disk causes the orthopedic hip brace attachment armto rotate with respect to the connecting plate when the first outer diskis mated with the orthopedic hip brace attachment arm slot; and rotatingthe second outer disk with respect to the second inner disk causes theorthopedic hip brace attachment arm to rotate with respect to theconnecting plate when the second outer disk is mated with the orthopedichip brace attachment arm slot.
 20. The adjustment device of claim 19,wherein the patterned raised section of the inner disk and the patternedprotruding portion of the outer disk each comprise a plurality ofv-grooves arranged in a radial pattern wherein a center line of eachv-groove is radially spaced a same number of degrees from an adjacentv-groove centerline.